Synthetic polyisoprene rubber

ABSTRACT

The neodymium catalyst system prepared by the technique of this invention can be used in the polymerization of isoprene monomer into synthetic polyisoprene rubber having an extremely high cis-microstructure content and high stereo regularity. This polyisoprene rubber will crystallize under strain and can be compounded into rubber formulations in a manner similar to natural rubber. This invention more specifically discloses a process for preparing a neodymium catalyst system which comprises ( 1 ) reacting a neodymium carboxylate with an organoaluminum compound in an organic solvent to produce neodymium-aluminum catalyst component, and ( 2 ) subsequently reacting the neodymium-aluminum catalyst component with an elemental halogen to produce the neodymium catalyst system. The present invention further discloses a synthetic polyisoprene rubber which is comprised of repeat units that are derived from isoprene, wherein the synthetic polyisoprene rubber has a cis-microstructure content which is within the range of 98.0% to 99.5%, a 3,4-microstructure content which is within the range of 0.5% to 2.0%, and a trans-microstructure content which is within the range of 0.0% to 0.5%.

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 60/531,040, filed on Dec. 19, 2003.

BACKGROUND OF THE INVENTION

Neodymium salts activated with aluminum alkyl co-catalysts have beenknown to catalyze the polymerization of conjugated dienes since theearly 1960's. To date, many papers and patents have been published whichdescribe variations and improvements to the original systems (see U.S.Pat. No. 3,297,667, U.S. Pat. No. 3,676,441, and U.S. Pat. No.3,794,604). Much of this work was driven by the eventualcommercialization of high cis-polybutadiene in the 1980s for the use intire applications (see U.S. Pat. No. 4,242,232, U.S. Pat. No. 4,260,707,U.S. Pat. No. 4,699,960, and U.S. Pat. No. 4,444,903).

The type of catalyst system employed and its method of preparation arecrucial to the success of the polymerization. Traditionally, there aretwo main types of catalyst systems, the first is a ternary system basedon soluble neodymium carboxylates in conjunction with an alkylaluminumco-catalyst and a halogen source (see R. P. Quirk, A. M. Kells, K.Yunlu, J. P. Cuif, Polymer 41, 5903 (2000) and A. Pross, P. Marquardt,K. H. Reichert, W. Nentwig, T. Knauf, Angew. Makromol. Chem. 211, 89(1993)). The second system is a binary catalyst comprising of aninsoluble neodymium halide complexed with three equivalence of a Lewisbase such as an alcohol, amine, or phosphonate and an alkylaluminumactivator (see H. Iovu, G. Hubca, E. Simionescu, E. Badea, J. S. Hurst,Eur. Polymer J. 33, 811 (1997); H. Iovu, G. Hubca, D. Racoti, J. S.Hurst, Eur. Polymer J. 35, 335 (1999); and J. H. Yang, M. Tsutsui, Z.Chen, D. Bergbreiter, Macromolecules 15, 230 (1982)).

In general, the two systems behave similarly; however, the ternarysystem appears to have gained acceptance commercially in the productionof polybutadiene (see D. J. Wilson, J. Polym. Sci., Part A. 33, 2505(1995)). Typically, the most active ternary systems consist of treatinga branched long chain neodymium carboxylate with branchedtrialkyl-aluminum or dialkylaluminum hydrides, in an Al/Nd ratio between10-40/1, and the use of 2-3 equivalents of a halide source, such asdiethylaluminum chloride or tert-butylchloride.

The active catalyst is typically prepared in one of two ways. Thesimplest method is to generate the catalyst in-situ by sequentiallyintroducing the catalyst components to the polymerization solution. Itis usually most effective to introduce the aluminum alkyl componentsfirst, thereby scavenging impurities from the premix prior to contactwith the neodymium salt. The other method for catalyst preparation is topreform the catalyst components prior to introducing them into thepolymerization vessel. The most common practice involves sequentiallytreating the catalyst components in the presence of at least a fewequivalents of monomer followed by an aging period. For example U.S.Pat. No. 3,794,604 discloses an improved preforming technique which iscarried out in the presence of a small portion of a conjugated diene.

Aging the catalyst components with a diene prior to polymerizationresults in a more active catalyst then when the conjugated diene isabsent. The disclosed technique for catalyst formation is to age afterall of the components have been mixed together. U.S. Pat. No. 4,429,089also teaches the use of a diolefin during catalyst formation and statesthat the particular procedure which is followed has no bearing on thepolymerization run. Likewise, U.S. Pat. No. 4,461,883 discloses that theuse of a conjugated diene in the catalyst make-up is preferable forimproving the activity of the catalyst. In this example, the diene ismixed with the catalyst components at any time in the preforming stepwith aging occurring after all components are mixed together.

U.S. Pat. No. 4,533,711 teaches the practice of adding the catalystcomponents together first followed by the addition of a small amount ofdiene and then aging the preformed catalyst. This patent states that thediene is not essential in the make-up but it does serve to increasecatalyst activity. U.S. Pat. No. 4,663,405 continues to teach the use ofconjugated dienes as components in preformed catalysts. It goes on tostate that soluble catalysts result when diolefins are present in themake-up while insoluble catalysts frequently result when no diene ispresent. This patent teaches a process where aging of the catalystoccurs after the reagents are added.

U.S. Pat. No. 5,502,126 again practices the use of a diene in thepreformed catalyst make-up and again states that it is preferred to agethe catalyst after the labile halogen compound is added. In U.S. Pat.No. 5,659,101 the use of a diolefin in conjunction with a boron derivedhalogen source results in a preformed catalyst that partially forms asolid precipitate in aliphatic solvents.

When silicone halides are used, as in U.S. Pat. No. 5,686,371, aging inthe presence of a diene again is performed after the addition of all thecatalyst components. U.S. Pat. No. 6,136,931 discloses an improved boronhalide dependent preformed catalyst that has excellent solubility innon-polar solvents. Finally, U.S. Pat. No. 6,255,416 also practicepreformed catalyst generation in the presence of a small amount ofdiene. Aging in this case again occurs after all of the catalystcomponents are mixed.

SUMMARY OF THE INVENTION

The neodymium catalyst system prepared by the technique of thisinvention can be used in the polymerization of isoprene monomer intosynthetic polyisoprene rubber having an extremely highcis-microstructure content and high stereo regularity. This polyisoprenerubber will crystallize under strain and can be compounded into rubberformulations in a manner similar to natural rubber. It can accordinglybe utilized in manufacturing a wide variety of rubber articles, such astires, hoses, and belts.

This invention more specifically discloses a process for preparing aneodymium catalyst system which comprises (1) reacting a neodymiumcarboxylate with an organoaluminum compound in an organic solvent toproduce neodymium-aluminum catalyst component, and (2) subsequentlyreacting the neodymium-aluminum catalyst component with an elementalhalide to produce the neodymium catalyst system.

The subject invention further reveals a process for the synthesis ofpolyisoprene rubber which comprises polymerizing isoprene monomer in thepresence of a neodymium catalyst system, wherein the neodymium catalystsystem is prepared by (1) reacting a neodymium carboxylate with anorganoaluminum compound in an organic solvent to produceneodymium-aluminum catalyst component, and (2) subsequently reacting theneodymium-aluminum catalyst component with an elemental halogen toproduce the neodymium catalyst system.

The present invention also discloses a synthetic polyisoprene rubberwhich is comprised of repeat units that are derived from isoprene,wherein the synthetic polyisoprene rubber has a cis-microstructurecontent which is within the range of 98.0% to 99.5%, a3,4-microstructure content which is within the range of 0.5% to 2.0%,and a trans-microstructure content which is within the range of 0.0% to0.5 %.

The present invention further reveals a pneumatic tire which iscomprised of a generally toroidal-shaped carcass with an outercircumferential tread, two spaced beads, at least one ply extending frombead to bead and sidewalls extending radially from and connecting saidtread to said beads; wherein said tread is adapted to beground-contacting; wherein the tread is comprised of (1) the syntheticpolyisoprene rubber specified in claim 19 and (2) at least one rubberypolymer selected from the group consisting of natural rubber,polybutadiene rubber, styrene-butadiene rubber.

DETAILED DESCRIPTION OF THE INVENTION

The neodymium catalyst system of this invention can be used in thepolymerization of isoprene monomer into polyisoprene rubber that willcrystallize under strain. Such polymerizations are typically conductedin a hydrocarbon solvent that can be one or more aromatic, paraffinic,or cycloparaffinic compounds. These solvents will normally contain from4 to 10 carbon atoms per molecule and will be liquids under theconditions of the polymerization. Some representative examples ofsuitable organic solvents include pentane, isooctane, cyclohexane,normal hexane, benzene, toluene, xylene, ethylbenzene, and the like,alone or in admixture.

In solution polymerizations that utilize the catalyst systems of thisinvention, there will normally be from 5 to 35 weight percent isoprenemonomer in the polymerization medium. Such polymerization mediums are,of course, comprised of an organic solvent, the isoprene monomer, andthe catalyst system. In most cases, it will be preferred for thepolymerization medium to contain from 10 weight percent to 30 weightpercent isoprene monomer. It is generally more preferred for thepolymerization medium to contain 12 weight percent to 18 weight percentisoprene monomer.

The neodymium catalyst system used in the process of this invention ismade by (1) reacting a neodymium carboxylate with an organoaluminumcompound in an organic solvent to produce neodymium-aluminum catalystcomponent, and (2) subsequently reacting the neodymium-aluminum catalystcomponent with an elemental halogen to produce the neodymium catalystsystem. In making the neodymium catalyst system the neodymiumcarboxylate and the organoaluminum compound are first reacted togetherfor a period of 1 minute to about 10 hours to make theneodymium-aluminum catalyst component. The neodymium carboxylate and theorganoaluminum compound are preferable reacted for a period of 10minutes to 45 minutes. This step can be conducted over a widetemperature range of from about 0° to about 150° C. The neodymiumcarboxylate and the organoaluminum compound will more typically bereacted at a temperature which is within the range of 5° C. to about105° C., and will preferable be conducted at a temperature which iswithin the range of 55° C. to about 85° C.

The neodymium-aluminum catalyst component is then reacted with at leastone elemental halogen of Group VII of the Periodic Table. The elementalhalogen will be selected from fluorine, chlorine, bromine, iodine,astatine, and any mixed halogen compounds such as iodine monochloride oriodine bromide. It is preferred to utilize fluorine, chlorine, orbromine as the elemental halogen. Fluorine and chlorine are preferredwith chlorine being most preferred. A mixture of elemental halogens canbe employed in the practice of the process of this invention. Forinstance, a mixture of fluorine and chlorine can be utilized as theelemental halogen.

The elemental halogen is reacted with the neodymium-aluminum componentby simply introducing the halogen into an organic solution of theneodymium-aluminum component. For instance, this can be accomplished bybubbling fluorine or chlorine gas through a solution of theneodymium-aluminum component in an organic solvent. However, it ispreferred to react the neodymium-aluminum component with an elementalhalogen which is pre-dissolved in an organic solvent. Such a solutioncontaining elemental halogen can be prepared by bubbling fluorine orchlorine gas through an organic solvent. These organic solvents normallycontain from 4 to 10 carbon atoms per molecule as defined previously.The concentration of these halogen solutions is normally ranged from0.05 to 2 M. This will normally be done at a temperature that is withinthe range of −10° C. to 80° C., and will preferably be done at atemperature that is within the range of 5° C. to 50° C. The elementalhalogen will generally be reacted with the neodymium-aluminum componentat room temperature (about 10° C. to about 30° C.).

The organoaluminum compound contains at least one carbon to aluminumbond and can be represented by the structural formula:

in which R₁ is selected from the group consisting of alkyl (includingcycloalkyl), alkoxy, aryl, alkaryl, arylalkyl radicals and hydrogen: R₂is selected from the group consisting of alkyl (including cycloalkyl),aryl, alkaryl, arylalkyl radicals and hydrogen and R₃ is selected from agroup consisting of alkyl (including cycloalkyl), aryl, alkaryl andarylalkyl radicals. Representative of the compounds corresponding tothis definition are: diethylaluminum hydride, di-n-propylaluminumhydride, di-n-butylaluminum hydride, diisobutylaluminum hydride,diphenylaluminum hydride, di-p-tolylaluminum hydride, dibenzylaluminumhydride, phenylethylaluminum hydride, phenyl-n-propylaluminum hydride,p-tolylethylaluminum hydride, p-tolyl-n-propylaluminum hydride,p-tolylisopropylaluminum hydride, benzylethylaluminum hydride,benzyl-n-propylaluminum hydride, and benzylisopropylaluminum hydride andother organoaluminum hydrides. Also included are ethylaluminumdihydride, butylaluminum dihydride, isobutylaluminum dihydride,octylaluminum dihydride, amylaluminum dihydride and other organoaluminumdihydrides. Also included are diethylaluminum ethoxide anddipropylaluminum ethoxide. Also included are trimethylaluminum,triethylaluminum, tri-n-propylaluminum, triisopropylaluminum,tri-n-propylaluminum, triisopropylaluminim, tri-n-butylaluminum,triisobutylaluminum, tripentylaluminum, trihexylaluminum,tricyclohexylaluminum, trioctylaluminum, triphenylaluminum,tri-p-tolylaluminum, tribenzylaluminum, ethyldiphenylaluminum,ethyl-di-p-tolylaluminum, ethyldibenzylaluminum, diethylphenylaluminum,diethyl-p-tolylaluminum, diethylbenzylaluminum and othertriorganoaluminum compounds.

The neodymium carboxylate utilizes an organic monocarboxylic acid ligandthat contains from 1 to 20 carbon atoms, such as acetic acid, propionicacid, valeric acid, hexanoic acid, 2-ethylhexanoic acid, neodecanoicacid, lauric acid, stearic acid and the like neodymium naphthenate,neodymium neodecanoate, neodymium octanoate, and other neodymium metalcomplexes with carboxylic acid containing ligands containing from 1 to20 carbon atoms.

The proportions of the catalyst components utilized in making theneodymium catalyst system of this invention can be varied widely. Themolar ratio of the trialkylaluminum or alkylaluminum hydride toneodymium metal can range from about 4/1 to about 200/1 with the mostpreferred range being from about 8/1 to about 100/1. Although,optionally, a small amount of diene monomer can be added to the catalystsystem as described in previous patents and literature, it was foundthat the neodymium catalyst system disclosed in this invention istotally soluble in organic solvent and stable at ambient temperaturewithout the use of such diene monomers.

The molar ratio of the elemental halogen to the neodymium compound willtypically be within the range of 0.1:1 to about 5:1. The molar ratio ofthe elemental halogen to the neodymium carboxylate will preferably bewithin the range of 0.5:1 to about 2:1. The molar ratio of the elementalhalogen to the neodymium carboxylate will most preferably be within therange of 0.3:1 to about 1.5:1.

The amount of catalyst used to initiate the polymerization can be variedover a wide range. Low concentrations of the catalyst system arenormally desirable in order to minimize ash problems. It has been foundthat polymerizations will occur when the catalyst level of the neodymiummetal is 0.03 or more millimole of neodymium metal per 100 grams ofmonomer. A preferred ratio is between 0.05 and 0.3 millimole ofneodymium metal per 100 grams of monomer.

The concentration of the total catalyst system employed, of course,depends upon factors such as purity of the system, polymerization ratedesired, temperature and other factors. Therefore, specificconcentrations cannot be set forth except to say that catalytic amountsare used.

Temperatures at which the polymerization reaction is carried out can bevaried over a wide range. Usually the temperature can be varied fromextremely low temperatures such as −60° C. up to high temperatures, suchas 150° C. or higher. Thus, the temperature is not a critical factor ofthe invention. It is generally preferred, however, to conduct thereaction at a temperature in the range of from about 10° C. to about 90°C. The pressure at which the polymerization is carried out can also bevaried over a wide range. The reaction can be conducted at atmosphericpressure or, if desired, it can be carried out at sub-atmospheric orsuper-atmospheric pressure. Generally, a satisfactory polymerization isobtained when the reaction is carried out at about autogenous pressure,developed by the reactants under the operating conditions used.

The polymerization can be terminated by the addition of an alcohol oranother protic source, such as water. Such a termination step results inthe formation of a protic acid. However, it has been unexpectedly foundthat better color can be attained by utilizing an alkaline aqueousneutralizer solution to terminate the polymerization. Another advantageof using an alkaline aqueous neutralizer solution to terminate thepolymerization is that no residual organic materials are added to thepolymeric product.

Polymerization can be terminated by simply adding an alkaline aqueousneutralizer solution to the polymer cement. The amount of alkalineaqueous neutralizer solution added will typically be within the range ofabout 1 weight percent to about 50 weight percent based upon the weightof the polyisoprene cement. More typically, the amount of the alkalineaqueous neutralizer solution added will be within the range of about 4weight percent to about 35 weight percent based upon the weight of thepolyisoprene cement. Preferable, the amount of the alkaline aqueousneutralizer solution added will be within the range of about 5 weightpercent to about 15 weight percent based upon the weight of thepolyisoprene cement.

The alkaline aqueous neutralizer solution will typically have a pH whichis within the range of 7.1 to 9.5. The alkaline aqueous neutralizersolution will more typically have a pH which is within the range of 7.5to 9.0, and will preferable have a pH that is within the range of 8.0 to8.5. The alkaline aqueous neutralizer solution will generally be asolution of an inorganic base, such as a sodium carbonate, a potassiumcarbonate, a sodium bicarbonate, a potassium bicarbonate, a sodiumphosphate, a potassium phosphate, and the like. For instance, thealkaline aqueous neutralizer solution can be a 0.25 weight percentsolution of sodium bicarbonate in water. Since the alkaline aqueousneutralizer solution is not soluble with the polymer cement it isimportant to utilize a significant level of agitation to mix thealkaline aqueous neutralizer solution into throughout the polymer cementto terminate the polymerization. Since the alkaline aqueous neutralizersolution is not soluble in the polymer cement it will readily separateafter agitation is discontinued.

The synthetic polyisoprene rubber made with the unique neodymiumcatalyst system of this invention is comprised of repeat units that arederived from isoprene (isoprene repeat units), wherein the syntheticpolyisoprene rubber has a cis-microstructure content which is within therange of 98.0% to 99.5%, a 3,4-microstructure content which is withinthe range of 0.5% to 2.0%, and a trans-microstructure content which iswithin the range of 0.0% to 0.5%. The synthetic polyisoprene rubber willhave a ratio of weight average molecular weight to the number averagemolecular weight that is within the range of 1.0 to 2.5. The syntheticpolyisoprene rubber will preferably have a ratio of weight averagemolecular weight to the number average molecular weight which is withinthe range of 1.25 to 2.15.

The synthetic polyisoprene rubber made with the novel neodymium catalystsystem of this invention has a stereo regularity of at least 99.0% andpreferably has a stereo regularity of at least 99.5%. In other words, atleast 99.0% and preferably 99.5 of the isoprene repeat units in thebackbone of the polymer chain are bound “head to tail” with less than 1%of the isoprene repeat units being connected “tail to tail” and/or “headto head.” The synthetic polyisoprene made with the catalyst system ofthis invention will crystallize under strain and has properties that aresimilar to natural rubber. It can accordingly be used as a partial ordirect replacement for natural rubber in a wide variety of applications,such as tires, hoses, and belts. It can also be blended with naturalrubber or synthetic rubber, such as high-cis-1,4-polybutadiene,styrene-butadiene rubber (made by solution or emulsion polymerization),or isoprene-butadiene rubber, for utilization in such applications. Ithas characteristics that are particularly useful in manufacturing rubbercompositions for tire treads.

The neodymium catalyst system of this invention can also be used in thepolymerization of other conjugated diene monomers such as 1,3-butadiene,2,3-dimethyl-1,3-butadiene, 1,3-pentadiene, 4-methyl-1,3-pentadiene,1,3-cyclohexadiene and mixtures of these conjugated diene monomers, suchas isoprene/1,3-butadiene, and isoprene/1,3-pentadiene.

This invention is illustrated by the following examples which are merelyfor the purpose of illustration and are not to be regarded as limitingthe scope of the invention or the manner in which it can be practiced.Unless specifically indicated otherwise, parts and percentages are givenby weight.

EXAMPLE 1

The preparation of an alkylated neodymium catalyst is described in thisexample. In the procedure used, 20 milliliters of a 0.506 M neodymiumneodecanoate (NdV₃) solution in hexanes was charged to a dried 8 oz (237ml.) bottle under nitrogen at room temperature. Then, 142 ml. of 1Mtri-n-octyl aluminum (TOA) in hexanes (the hexanes solvent used was amixture of various hexane isomers) was slowly added to above NdV₃solution. The resulting light blue mixture was then heated in a rotatingpolymerization bath at 70° C. for 10 to 60 minutes. The molar ratio ofTOA to Nd was 14:1. The solution turned darker brown color in less than10 minutes. The concentration of this Nd catalyst was 0.063 M. Otheralkylated Nd catalysts were prepared similarly with tri-ethylaluminum(TEA), tri-isobutyl aluminum (TIBA), di-isobutylaluminum hydride (DIBAH)and tri-n-hexyl aluminum (THA). All alkylated Nd catalysts were solublein hexanes solvent. These alkylated Nd catalysts can be prepared in aheated loop or a mixer outside of a polymerization reactor prior to useas the co-catalyst for polymerization in a batch or a continuoussystems.

EXAMPLE 2

In this example, an active preformed neodymium catalyst was prepared.0.47 ml of a neat t-amyl chloride (t-AmCl, 7.96 M) was added dropwise,with shaking, to a 4 oz (118 ml.) bottle containing 30 ml. of apre-alkylated Nd catalyst (0.063 M as described in Example 1) at roomtemperature. A vigorous reaction took place. The resulting light brownmixture was used for polymerizing isoprene 1,3-butadiene or a mixture of1,3-butadiene and isoprene. The molar ratio of Nd to TOA and to t-AmClwere 1:14:2.

EXAMPLE 3

In this experiment, a polyisoprene was prepared using a preformed Ndcatalyst as described in Example 2. In the procedure used 2000 grams ofa silica/alumina/molecular sieve dried premix containing 19.90 weightpercent isoprene in hexanes was charged into a one-gallon (3.8 liter)reactor. Then, 14.1 ml of a preformed Nd catalyst made by the proceduredescribed in Example 2 was added to the reactor. The amount of Nd usedwas 0.22 mmole per 100 grams of isoprene monomer.

The polymerization was carried out at 90° C. The GC analysis of theresidual monomer contained in the polymerization mixture indicated thatthe 90% of isoprene monomer was consumed after 14 minutes. Thepolymerization was continued for an additional 30 minutes. Then, 1 ml.of neat ethanol was added to shortstop the polymerization. The polymercement was then removed from the reactor and stabilized with 1 phm ofantioxidant. After evaporating hexanes, the resulting polymer was driedin a vacuum oven at 50° C.

The polyisoprene produced was determined to have a glass transitiontemperature (Tg) at −67° C. It was then determined to have amicrostructure, which contained 95.6 percent cis-1,4-polyisoprene units,1.4 percent trans-1,4-polyisoprene units, and 3.0 percent3,4-polyisoprene units. The Mooney viscosity (ML-4) at 100° C. for thispolymer was determined to be 82. This polymer was also determined tohave a stereo regularity count (head to tail) of 99.6%. The GPCmeasurements indicated that the polymer has a number average molecularweight (Mn) of 429,000 and a weight average molecular weight (Mw) of1,032,000. The polydispersity (Mw/Mn) of the resulting polymer wasdetermined to be 2.41.

COMPARATIVE EXAMPLE 4

In this example, a polyisoprene was prepared using a pre-alkylated Ndcatalyst as described in Example 1 and the co-catalyst t-AmCl was addedseparately to the reactor containing isoprene monomer. The proceduredescribed in Example 3 was utilized in this example except that apre-alkylated Nd catalyst (as described in Example 1) was used as theco-catalyst and, 1.75 ml of a 1M solution of t-AmCl (in hexane) wassubsequently added to the reactor containing isoprene premix in thereactor. The GC analysis of the residual monomer contained in thepolymerization mixture indicated that 90 percent of isoprene wasconsumed after 350 minutes at 90° C. The polymerization was continuedfor an additional 30 minutes. The polymer was then recovered asdescribed in Example 3. The resulting polymer had a glass transitiontemperature (Tg) at −67° C. It was also determined to have a Mooneyviscosity (ML-4) at 100° C. of 72. The GPC measurements indicated thatthe polymer has a number average molecular weight (Mn) of 476,000 and aweight average molecular weight (Mw) of 1,182,000. The polydispersity(Mw/Mn) of the resulting polymer was 2.48. A rate and polymercharacteristics comparison of the polyisoprenes prepared using Ndcatalysts described in Examples 1 and 2 are tabulated in Table 1. TABLE1 Example Time to 90% Tg Molecular weight by GPC No Catalyst conversion(min.) (° C.) ML-4 Mn Mw Mw/Mn 3 Preformed Nd with t-AmCl  14 −67 82429K 1,032K 2.41 4 Pre-alkylated Nd with 350 −67 72 476K 1,182K 2.48t-AmCl added separately

EXAMPLE 5

In this experiment, a 30/70 isoprene-butadiene rubber (IBR) was preparedusing a preformed catalyst described in Example 2. The proceduredescribed in Example 3 was utilized in this examples except that apremix containing a 30:70 mixture of isoprene and 1,3-butadiene was usedas the monomers. GC analysis of the residual monomer indicated that 90percent of monomers were consumed after 9 minutes. The polymerizationwas continued for an additional 21 minutes.

The resulting IBR was then recovered as described in Example 3. It wasdetermined to have a glass transition temperatures at −102° C. TheMooney viscosity (ML-4) at 100° C. for this polymer was determined to be102. It was then determined to have a microstructure which contained67.7 percent cis-1,4-polybutadiene units, 1.4 percenttrans-1,4-polybutadiene units, 0.8 percent 1,2-polybutadiene unit, 28.9percent cis-1,4-polyisoprene units, 0.3 percent trans-1,4-polyisopreneunit, and 0.9 percent 3,4-polyisoprene unit. The GPC measurementsindicated that the IBRs has a number average molecular weight (Mn) of427,000 and a weight average molecular weight (Mw) of 1,029,000. Thepolydispersity (Mw/Mn) of the resulting polymer was 2.14.

COMPARATIVE EXAMPLE 6

In this example, a 30/70 IBR was prepared using the procedure describedin Example 4 except that a premix containing a 30:70 mixture of isopreneand 1,3-butadiene was used as the monomers. The GC analysis of theresidual monomer contained in the polymerization mixture indicated that90% of isoprene was consumed after 276 minutes at 90° C. Thepolymerization was continued for an additional 30 minutes. The polymerwas then recovered as described in Example 3. The resulting polymer hada Tg at −102° C. It was also determined to have a Mooney viscosity(ML-4) at 100° C. of 103. The GPC measurements indicated that thepolymer has a number average molecular weight (Mn) of 417,000 and aweight average molecular weight (Mw) of 1.021,000. The polydispersity(Mw/Mn) of the resulting polymer is 2.44. A rate and polymercharacteristics comparison of the IBRs prepared using Nd catalystsdescribed in Examples 1 and 2 are tabulated in Table 2. TABLE 2 ExampleTime to 90% Tg Molecular weight by GPC No Catalyst conversion (min.) (°C.) ML-4 Mn Mw Mw/Mn 5 Preformed Nd with t-AmCl  9 −102 102 427K 1,029K2.41 6 Pre-alkylated Nd with 276 −102 103 417K 1,021K 2.48 t-AmCl addedseparately

EXAMPLES 7-8

In these examples, polyisoprenes are prepared using a preformed Ndcatalyst as described in Example 2. The molar ratio of Nd to TOA and tot-AmCl was 1:14:2. The procedure described in Example 3 was utilized inthese examples except that the polymerization temperature was changed to60° C. and 40° C., respectively. The time needed for 90% monomerconversion, Tg and ML-4 of the resulting polyisoprenes are listed inTable 3. TABLE 3 Ex- Polymerization Time to 90% ample Nd/TOA/t-AmClTemperature Conversion Tg No. Ratio (° C.) (min.) (° C.) ML-4 3 1/14/290 14 −67 82 7 1/14/2 60 21 −67 86 8 1/14/2 40 80 −67 95

EXAMPLES 9-11

In these examples, polyisoprenes were prepared using a preformed Ndcatalyst as described in Example 2. However, the molar ratio of Nd toTOA and to t-AmCl was changed to 1:10:2. The procedure described inExample 3 was utilized in these examples and the polymerizations wereconducted at 90° C., 75° C., and 60° C. The time needed to attain 90percent monomer conversion, Tg, and ML-4 of the resulting polyisoprenesare listed in Table 4. TABLE 4 Ex- Polymerization Time to 90% ampleNd/TOA/t-AmCl Temperature Conversion Tg No. Ratio (° C.) (min.) (° C.)ML-4  9 1/10/2 90 12 −67 82 10 1/10/2 75 23 −67 87 11 1/10/2 60 60 −6791

EXAMPLES 12-14

In these examples, polyisoprenes are prepared using a preformed Ndcatalyst as described in Example 2. However, the molar ratio of Nd toTOA and to t-AmCl was changed to 1:20:2. The procedure described inExample 3 was utilized in these examples and the polymerization wereconducted at 90° C., 75° C., and 60° C. The time needed for 90% monomerconversion, Tg, and ML-4 of the resulting polyisoprenes are listed inTable 5. TABLE 5 Ex- Polymerization Time to 90% ample Nd/TOA/t-AmClTemperature Conversion Tg No. Ratio (° C.) (min.) (° C.) ML-4 12 1/20/290 17 −67 53 13 1/20/2 75 23 −67 77 14 1/20/2 60 60 −67 90

EXAMPLES 15-17

In these examples, polyisoprenes are prepared using a preformed Ndcatalyst as described in Example 2. However, the molar ratio of Nd toTOA and to t-AmCl was changed to 1:30:2. The procedure described inExample 3 was utilized in these examples and the polymerization wereconducted at 90° C., 75° C., and 60° C. The time needed for 90% monomerconversion, Tg and ML-4 of the resulting polyisoprenes are listed inTable 6. TABLE 6 Ex- Polymerization Time to 90% ample Nd/TOA/t-AmClTemperature Conversion Tg No. Ratio (° C.) (min.) (° C.) ML-4 15 1/30/290 20 −67 40 16 1/30/2 75 26 −67 51 17 1/30/2 60 80 −67 77

EXAMPLE 18

In this example, a chlorine in hexane solution was prepared. In theprocedure used, 1,500 grams of dried hexane was added to a one-gallon(3.8 liter) nitrogen filled pressurized stainless steel cylinder. Thecylinder was cooled in an ice bath. Then, 80.7 grams of chlorine gas wasadded to the cylinder. The concentration of chlorine in hexane was 0.5M. As estimated using the Raoult's law, the chlorine was fairly solublein the organic solvent. The estimated chlorine solubility (weightpercent) in hexane is shown in Table 7. TABLE 7 Estimated ChlorineSolubility in n-Hexane, Weight % Pressure Temperature, °F. (psia) 60 7080 90 100 14.7 11.6 9.7 8.0 6.6 5.3 25 21.5 18.2 15.4 13.1 11.1 35 31.626.8 22.9 19.6 16.8

EXAMPLE 19

In this example, a polyisoprene rubber was prepared. The proceduredescribed in Example 3 was utilized in this experiment except thatchlorine was used as the chloride source and the polymerizationtemperature was 70° C. The chlorine in hexane solution was prepared bybubbling chlorine gas in to hexane solution. The molarity of chlorinewas 1.06 M. GC analysis of the residual monomer indicated that 90% ofisoprene was consumed after 2.5 hours. The polymerization was continuedfor an additional 30 minutes. The polymer was recovered as described inExample 3. The resulting polymer had a Tg at −67° C. It was alsodetermined to have a Mooney viscosity (ML-4) at 100° C. of 74. The GPCmeasurements indicated that the polymer has a number average molecularweight (Mn) of 550,000 and a weight average molecular weight (Mw) of1,090,000. The polydispersity (Mw/Mn) of the resulting polymer was 1.98.

EXAMPLE 20

In this example, a polyisoprene was prepared. The procedure described inExample 18 was utilized in this experiment except that only a halfamount of chlorine was used. The molar ratio of Nd to TOA and tochlorine was 1:14:1. GC analysis of the residual monomer indicated that98% of isoprene was consumed after 45 minutes. The polymer was recoveredas described in Example 3. The resulting polymer had a Tg at −67° C. TheGPC measurements indicated that the polymer has a number averagemolecular weight (Mn) of 1,000,000 and a weight average molecular weight(Mw) of 1,700,000. The polydispersity (Mw/Mn) of the resulting polymerwas 1.70.

EXAMPLE 21

A higher molecular weight polyisoprene was prepared in this example. Theprocedure described in Example 18 was used in this example except thepolymerization temperature and catalyst concentration was changed to 40°C. and 0.065 mmoles/100 g of monomer, respectively.

The resulting polymer had a Tg at −67° C. It was also determined to havea Mooney viscosity (ML-4) at 100° C. of 94. GC analysis of residualmonomer indicated that 90 percent of isoprene was consumed in 7 hours.The polymerization was continued for an additional hour and the polymerwas recovered as described in Example 3. The GPC measurements indicatedthat the polymer has a number average molecular weight (Mn) of 1,428,000and a weight average molecular weight (Mw) of 2,358,000. Thepolydispersity (Mw/Mn) of the resulting polymer was 1.75. The polymerwas also determined to have a microstructure containing 98.1 percentcis-1,4-polyisoprene units, 1.8 percent of 3,4-polyisoprene units, and0.1 percent trans-1,4 polyisoprene units. NMR also determined that thispolyisoprene has very high stereo regularity since it contained only 0.2percent of head-to-head and 0.2 percent of tail-to-tail structures.

EXAMPLE 22

A higher molecular weight polyisoprene was prepared in this example. Theprocedure described in Example 19 was used in this example except thepolymerization temperature and catalyst concentration was changed to 40°C. and 0.065 mmoles/100 g of monomer, respectively. The molar ratio ofNd to TOA and to chlorine was 1:14:1. GC analysis of the residualmonomer indicated that 94 percent of isoprene was consumed after 4hours. The polymerization was continued for an additional hour and thepolymer was recovered as described in Example 3. The resulting polymerhas a Tg at −67° C. The GPC measurements indicated that the polymer hasa number average molecular weight (Mn) of 1,420,000 and a weight averagemolecular weight (Mw) of 2,420,000. The polydispersity (Mw/Mn) of theresulting polymer was 1.70.

EXAMPLE 23

A polyisoprene was prepared in this example. The procedure described inExample 18 was used in this example except that the iodine monochloridewas used as the halogen source. The resulting polymer had a Tg at −67°C. It was also determined to have a Mooney viscosity (ML-4) at 100° C.of 74. The GPC measurements indicated that the polymer has a numberaverage molecular weight (Mn) of 597,000 and a weight average molecularweight (Mw) of 1,310,000. The polydispersity (Mw/Mn) of the resultingpolymer is 2.19.

EXAMPLE 24

A polyisoprene was prepared in this example. The procedure described inExample 3 was used in this example except that the iodine was used asthe halogen source. The resulting polymer had a Tg at −66° C. GCanalysis indicated that all of the isoprene was converted in 2.5 hours.

EXAMPLE 25

A polybutadiene was prepared in this example. The procedure described inExample 18 was used in this example except that the 1,3-butadiene wasused as the monomer. GC analysis indicated that all butadiene wasconverted in 1 hour. The resulting polymer had a Tg at −111° C. and a Tmat −15° C. It was also determined to have a Mooney viscosity (ML-4) at100° C. of 23. The GPC measurements indicated that the polymer had anumber average molecular weight (Mn) of 144,000 and a weight averagemolecular weight (Mw) of 332,000. The polydispersity (Mw/Mn) of theresulting polymer was 2.31.

EXAMPLE 26

In this example, a polyisoprene was prepared. The procedure described inExample 3 was utilized in this experiment except that iodinemonochloride (ICl) was used as the halide source and the polymerizationtemperature was 70° C. The molar ratio of Nd to TOA and to ICl was1:14:2. GC analysis of the residual monomer indicated that 90% ofisoprene was consumed after 2.5 hours. The polymerization was continuedfor an additional 60 minutes. The polymer was recovered as described inExample 3. The resulting polymer has a Tg at −66° C. It was alsodetermined to have a Mooney viscosity (ML-4) at 100° C. of 82. The GPCmeasurements indicated that the polymer has a number average molecularweight (Mn) of 597,000 and a weight average molecular weight (Mw) of1,310,000. The polydispersity (Mw/Mn) of the resulting polymer was 2.19.

EXAMPLE 27

A neodymium polyisoprene made in Example 20 (Nd-PI), a nature rubber(NR), a polyisoprene made with a titanium catalyst (Ti-PI) and Purforma®polyisoprene were pressed into rubber sheets at 100° C. in a mold for 15minutes under 25 ton pressure. After degassing, the rubber sheets werecooled overnight under pressure and cut into standard dumbbellsaccording to ASTM D412 method. The samples were tested in an UTS STM-LEmachine at a rate of 50.8 mm/minute at room temperature. The thicknesswere measured at different positions and averaged for stresscalculations. The width and length of samples were set as 6.36 mm and25.39 mm, respectively. All samples were very carefully loaded withoutintroducing any pre-stress. All tests were conducted until failure ofsamples, and the breaking areas were always fallen in the designatedarea (or otherwise the sample would be discarded). The results arereported in Table 7 and shown in the attached graph. It is noticed thatthe neodymium polyisoprene showed significant necking and much higherelongation at break. The difference in the observed stress-strain curvesis noticeable both in the shape and in the values. TABLE 8 Nd-PI NRTi-PI Purforma ® PI Tensile Strength at Break, 1.07 0.54 0.25 0.24 MPaElongation at Break, % 1288 593 436 997  50% Modulus, MPa 0.39 0.31 0.240.24 100% Modulus, MPa 0.21 0.18 0.13 0.13

EXAMPLE 28

Comparative rubber samples were prepared with natural rubber, Natsyn®2200 (synthetic polyisoprene), unmodified Purforma® (neodymium syntheticpolyisoprene) and the Cl-modified neodymium synthetic polyisoprene(Example 21). Carbon black was individually added to these polymersusing the recipe of Table 9 in a non-productive mix using a lab scalebanbury mixer. A second pass banbury mix as indicated in Table 9 wasused to add the curatives for obtaining cured rubber samples fortesting. TABLE 9 Non-Productive Banbury Mix (4 min @160° C.) NaturalRubber(TSR20 Grade) 100 Carbon Black (ASTM 299) 50 Processing Oil(Flexon 641 from ExxonMobil) 5 Zinc Oxide 5 Stearic Acid 2 Antioxidant(Flectol TMQ from Flexsys) 2 Productive Banbury Mix (2 min @ 110° C.)Benzothiazyl-2-Tert-butyl sulfenamide 1 Sulfur 1.4

The results in Table 10 compare the cured properties of natural rubberwith the various synthetic polyisoprenes. Samples for testing were cured32 min at 150° C. Rheometer was run at 150° C. Hot rebound is at 100° C.test temperature. Strebler tear is a peel adhesion tear test which isconducted at 95° C. The green strength results for NR and the newCl-modified neodymium polyisoprene are equivalent. The green strengthvalue represents the stress required to stretch an uncured rubbercompound to an elongation of 120%. Higher values are considered betterfor tire component applications. The Natsyn® 2200 synthetic polyisopreneand the unmodified neodymium polyisoprenes have low green strengthvalues. The 300% modulus values from stress strain testing and hotrebound values are fairly equivalent for all rubber compounds in thisseries. Low strain stiffness as measured by dynamic viscoelastic testingat 60° C., show somewhat higher values for the synthetic polyisoprenes.Tan delta values, which are a measure of a compound hysteresis (lower isbetter), when measured at 60° C. are also slightly lower for thesynthetic polyisoprenes. Unexpectedly, the tear strength values for theCl-modified neodymium polyisoprene are far superior to the othersynthetic polyisoprenes and approach the tear strength of naturalrubber. At the 50/50 blend ratio of synthetic polymer and naturalrubber, which is shown in parentheses, the Cl-modified polyisoprene isagain, surprisingly far superior to the other synthetic polyisoprenes.DIN abrasion which is a measurement of compound abradibility showsfairly equivalent values for all compounds. Tack strength for theCl-modified Neodymium polyisoprene is clearly superior to the othersynthetic polyisoprenes and somewhat comparable to natural rubber. Tackis very critical for building tire components, one on top of each otherprior to the curing of a tire.

These lab properties clearly indicate the unexpected performance of thisnew novel polymer when evaluated in a tire tread type application. Theimprovement of tack and green strength of uncured rubber compounds andthe dramatic improvement in cured compound tear strength is trulyunique. TABLE 10 Purforma ® CL Mod Polymers NR Natsyn Nd PI Nd PI Mooney66 77 81 92 Green Str (120%) .47 .28 .33 .42 RheometerT90 13 12.8 16.617.8 300% Modulus 12.6 11.2 11.3 10.4 Hot Rebound 60 61 61 61 G′ @ 10%1270 1436 1434 1356 TD @ 10% .103 .095 .090 .098 Strebler Tear 176 128(157) 115 (139) 152 (172) Instron Tear 435 418 411 627 DIN Abrasion 125120 130 126 Tack 16.9 9.5 9.3 14.4

While certain representative embodiments and details have been shown forthe purpose of illustrating the subject invention, it will be apparentto those skilled in this art that various changes and modifications canbe made therein without departing from the scope of the subjectinvention.

1. A process for preparing a neodymium catalyst system which comprises(1) reacting a neodymium carboxylate with an organoaluminum compound inan organic solvent to produce neodymium-aluminum catalyst component, and(2) subsequently reacting the neodymium-aluminum catalyst component withan elemental halogen to produce the neodymium catalyst system.
 2. Aprocess as specified in claim 1 wherein the elemental halide isfluorine.
 3. A process as specified in claim 1 wherein the elementalhalide is chlorine.
 4. A process as specified in claim 1 wherein theelemental halide is bromine.
 5. A process as specified in claim 1wherein the elemental halide is iodine.
 6. A process as specified inclaim 1 wherein the elemental halide is astatine.
 7. A process asspecified in claim 1 wherein the neodymium carboxylate is reacted withthe organoaluminum compound at a temperature that is within the range of0° C. to 150° C.
 8. A process as specified in claim 1 wherein the molarratio of the elemental halogen to the neodymium carboxylate is withinthe range of 0.1:1 to about 5:1.
 9. A process as specified in claim 1wherein the molar ratio of the elemental halogen to the neodymiumcarboxylate is within the range of 0.5:1 to about 2:1.
 10. A process asspecified in claim 1 wherein the molar ratio of the elemental halide tothe neodymium carboxylate is within the range of 0.3:1 to about 1.5:1.11. A process as specified in claim 1 wherein the mole ratio of theorganoaluminum compound to the neodymium carboxylate is within the rangeof about 4/1 to about 200/1.
 12. A process as specified in claim 1wherein the organoaluminum compound is selected from the groupconsisting of trialkylaluminum compounds and dialkylaluminum hydridecompounds.
 13. A process as specified in claim 1 wherein the mole ratioof the organoaluminum compound to the neodymium carboxylate is withinthe range of about 10/1 to about 50/1.
 14. A process as specified inclaim 1 wherein said organoaluminum compound is selected from the groupconsisting of diethylaluminum hydride, di-n-propylaluminum hydride,di-n-butylaluminum hydride, diisobutylaluminum hydride, diphenylaluminumhydride, di-p-tolylaluminum hydride, dibenzylaluminum hydride,phenylethylaluminum hydride, phenyl-n-propylaluminum hydride,p-tolyethylalumin hydride, p-tolyl-n-propylaluminum hydride,p-tolylisopropylaluminum hydride, benzylethylaluminum hydride,benzyl-n-propylaluminum hydride, benzylisopropylaluminum hydride,ethylaluminum dihydride, butylaluminum dihydride, isobutylaluminumdihydride, octylaluminum dihydride, amylaluminum dihydride,trimethylaluminum, triethylaluminum, tri-n-propylaluminum,triisopropylaluminum, tri-n-propylaluminum, triisopropylaluminum,tri-n-butylaluminum, triisobutylaluminum, tripentylaluminum,trihexylaluminum, trioctylaluminum, triphenylaluminum,tri-p-tolyaluminum, tribenylaluminum, ethyldiphenylaluminum,ethyl-di-p-tolylaluminum, ethyldibenzylaluminum, diethylphenylaluminum,diethyl-p-tolylaluminum, and diethylbenzylaluminum.
 15. A process asspecified in claim 1 wherein the neodymium carboxylate is selected fromthe group consisting of neodymium octoate, neodymium neodecanoate, andneodymium 2-ethyl hexanoate.
 16. A process for the synthesis ofpolyisoprene rubber which comprises polymerizing isoprene monomer in thepresence of a neodymium catalyst system, wherein the neodymium catalystsystem is prepared by (1) reacting a neodymium carboxylate with anorganoaluminum compound in an organic solvent to produceneodymium-aluminum catalyst component, and (2) subsequently reacting theneodymium-aluminum catalyst component with an elemental halogen toproduce the neodymium catalyst system.
 17. A process as specified inclaim 16 wherein the polymerization is conducted in an organic solvent.18. A process as specified in claim 16 wherein the polymerization iscarried out at a temperature within the range of about 10° C. to about90° C.
 19. A synthetic polyisoprene rubber which is comprised of repeatunits that are derived from isoprene, wherein the synthetic polyisoprenerubber has a cis-microstructure content which is within the range of98.0% to 99.5%, a 3,4-microstructure content which is within the rangeof 0.5% to 2.0%, and a trans-microstructure content which is within therange of 0.0% to 0.5%.
 20. A synthetic polyisoprene rubber as specifiedin claim 19 wherein the ratio of the weight average molecular weight tothe number average molecular weight of the synthetic polyisoprene rubberis within the range of 1.0 to 2.5.
 21. A synthetic polyisoprene rubberas specified in claim 19 wherein the ratio of the weight averagemolecular weight to the number average molecular weight of the syntheticpolyisoprene rubber is within the range of 1.25 to 2.15.
 22. A syntheticpolyisoprene rubber as specified in claim 19 wherein the syntheticpolyisoprene rubber has a stereo regularity of at least 99.0%.
 23. Asynthetic polyisoprene rubber as specified in claim 20 wherein thesynthetic polyisoprene rubber has a stereo regularity of at least 99.5%.24. A process as specified in claim 1 wherein the elemental halogen is amixture of at least 2 Group VII elements.
 25. A process as specified inclaim 24 wherein the elemental halogen is a mixture of fluorine andchlorine.
 26. A rubber blend composition which is comprised of (1) thesynthetic polyisoprene rubber specified in claim 19 and (2) at least onerubbery polymer selected from the group consisting of natural rubber,polybutadiene rubber, styrene-butadiene rubber.
 27. A rubber blend asspecified in claim 26 wherein the polybutadiene rubber has acis-microstructure content of at least 96 percent.
 28. A rubbery polymerblend as specified in claim 26 wherein the styrene-butadiene rubber ismade by an emulsion polymerization process.
 29. A rubbery polymer blendas specified in claim 26 wherein the styrene-butadiene rubber is made bya solution polymerization process.
 30. A rubbery polymer blend asspecified in claim 26 wherein the rubbery polymer is cured with sulfur.31. A rubbery polymer blend as specified in claim 30 which is furthercomprised of at least one filler selected from the group consisting ofcarbon black and silica.
 32. A pneumatic tire which is comprised of agenerally toroidal-shaped carcass with an outer circumferential tread,two spaced beads, at least one ply extending from bead to bead andsidewalls extending radially from and connecting said tread to saidbeads; wherein said tread is adapted to be ground-contacting; whereinthe tread is comprised of (1) the synthetic polyisoprene rubberspecified in claim 19 and (2) at least one rubbery polymer selected fromthe group consisting of natural rubber, polybutadiene rubber,styrene-butadiene rubber.
 33. A pneumatic tire which is comprised of agenerally toroidal-shaped carcass with an outer circumferential tread,two spaced beads, at least one ply extending from bead to bead andsidewalls extending radially from and connecting said tread to saidbeads; wherein said tread is adapted to be ground-contacting; whereinthe tread is comprised of the synthetic polyisoprene rubber specified inclaim
 19. 34. A tire as specified in claim 33 wherein the syntheticpolyisoprene rubber is cured with sulfur.
 35. A rubbery polymer blend asspecified in claim 34 wherein the tread is further comprised of at leastone filler selected from the group consisting of carbon black andsilica.